Abstract: Methods and apparatus for forming a plurality of uniformly sized solder balls utilize a stencil having a plurality of holes of uniform volume disposed on a substrate. Solder is disposed in the holes of the stencil on the substrate. Typically, the solder is in the form of solder paste which is distributed into the holes using a squeegee. While within the holes of the stencil on the substrate, the solder is melted to form solder balls. The stencil may then be removed to leave the solder balls on the substrate, or the solder balls may be removed while the stencil remains on the substrate.

Abstract: Start with a semiconductor substrate with contacts exposed through an insulating layer. Form a base over the contacts, with the base composed of at least one metal layer. Then form a conductive metal layer over the base. Form a mask over the top surface of the conductive metal layer with C4 solder bump openings therethrough with the shape of C4 solder bump images down to the surface of the conductive metal layer above the contacts. Etch away the exposed portions of the conductive metal layer below the C4 solder bump openings to form through holes in the conductive metal layer exposing C4 solder bump plating sites on the top surface of the base below the C4 solder bump openings with the conductive metal layer remaining intact on the periphery of the through holes at the C4 solder bump plating sites. As an option, form a barrier layer over the plating sites next.

Abstract: A face plate 11 is butted against a frame 520, from which a segment 525 for overlapping with the rear surface of a face plate 21 is projected. The frame 520 includes a raised portion 523. A friction stir welding is performed by inserting a rotary tool 50 into the raised portion 523. The rotary tool 50 is rotated clockwise as seen from the large-diameter portion 51, so that the pressure of fluidized metal is higher at the right-hand side of the axial center of the rotary tool 50. There exists the overlapping surface of the face plate 21 and the projecting segment 525 at the side with high pressure of metal. The raised portion 523 exists at the left-hand side of the axial center of the rotary tool 50. Thus, the occurrence of continuous metal oxide or a notch at the overlapping surface can be restrained.

Abstract: The invention relates to MSG-soldering (metal shielding gas-soldering) of metallic materials with use of soldering and an electric arc with consumable electrode or non-consumable electrode, whereby a shielding gas that essentially consists of inert gas is used. According to the invention, the shielding gas contains at least one active gas component in addition to the inert gas. As active gases, oxygen and/or carbon dioxide can be used. The proportion of active gas in the shielding gas is preferably in the range of 0.01 to 0.5% by volume.

Abstract: A method of fabricating a metal step shelf tray that has a series of trays at stepped elevated heights. The method includes providing a planar sheet of stainless steel and cutting a planar blank from the sheet. The planar blank includes a number of tray panel sections spaced from each other, a riser panel section between adjacent pairs of tray panel sections, and a pair of side panel sections extending out from opposite sides of each tray panel section. The planar blank may further include end riser sections extending from the free ends of the planar blank, and lower lip sections extending out from each of the side panel sections. The planar blank is then formed by a series of bending operations where the lower lip sections are directed perpendicular to their adjacent side panel sections; and the side panel sections, rise panel sections, and end riser sections are directed perpendicular to their adjacent tray panel sections.

Abstract: The welding apparatus has a positioner (1) provided with workpiece supporting means (11) which is rotatable about a first central axis (Ca) and is pivotable up and down about a second central axis (Cb) crossing the first central axis (Ca). A welding robot (2) includes a robot body (20) mounted on the workpiece supporting means (11). Therefore, even when the workpiece supporting means (11) operates, it is possible to prevent a torch (3) carried by the robot body (20) from positionally deviating relative to a workpiece (W) supported on the work supporting means (11).

Abstract: A method and apparatus for projection welding a metal fastener (e.g., a nut) to a metal member (e.g., a sheet) is disclosed. The apparatus includes a first electrical contact and a locator assembly having a second electrical contact. For welding the fastener to the member, the locator assembly aligns through-holes of the fastener and sheet and a current is passed through protrusions of the fastener. In turn, the protrusions are softened to bond with the member.

Abstract: Improvements in critical current capacity for superconducting film structures are disclosed and include the use of a superconducting RE-BCO layer including a mixture of rare earth metals, e.g., yttrium and europium, where the ratio of yttrium to europium in the RE-BCO layer ranges from about 3 to 1 to from about 1.5 to 1.

Abstract: Link arms for use in suspension systems are produced through an extrusion and friction stir welding process. Blocks having an eye and a planar body section are formed through an extrusion process. These sections are then paired together and joined through friction stir welding. The welded joint(s) is/are positioned in such a location so as to not impact the structural integrity of the completed component. Through this process it is possible to construct cost competitive link arms having the same or better structural integrity as previously employed steel link arms while achieving dramatic weight reductions.

Abstract: The invention concerns a method which can be carried out with a sensor device, for monitoring a laser machining operation to be performed on a work piece (12), in which for quality assurance with a local-resolution receiver assembly (10, 11, 14) a given field of observation (13) is selected in the region of the interaction zone between laser beam (25) and work piece (12), in which radiation coming from the selected field of observation (13) is detected with a radiation-sensitive receiver (10) which delivers an electrical signal corresponding to the detected radiation, in which the electrical signal is filtered in a signal processing circuit (16) in order to detect rapid and/or short, fault-related changes in intensity of the detected radiation, and in which the filtered electrical signal for the detection of faults during the laser machining operation.

Abstract: Disclosed is a friction stir welding technique which avoids occurrence of a dent, in adjoining region, extending to a level beneath the joined surfaces, structural body formed. At end portions of the frame members to be joined, at the joining region, thickened parts which project toward the rotary body joining tool are provided. The rotary body joining tool has a small-diameter tip portion and a larger diameter portion. The rotary body joining tool is inserted in the thickened parts. In a state where the rotary body joining tool has been inserted small-diameter tip end first, to a level where the larger diameter portion of the rotary body joining tool overlaps the thickened part but does not extend below the upper surface of the non-thickened surfaces of the members joined, the rotary body is rotated and moved along the joining region.

Abstract: A tension mechanism that applies a back tension to a wire in a bonding apparatus including: a first nozzle which has a through-hole through which the wire passes, second and third nozzles which have diameters that are larger than the diameter of the through-hole of the first nozzle and which are disposed above and below the first nozzle, a first air passage formed in the joining surfaces of the first nozzle and second nozzle, and a second air passage formed in the joining surfaces of the second nozzle and third nozzle. A compressed air supply device is connected to the tension mechanism and supplies compressed air to the first air passage from an air supply source, and a vacuum suction device is also connected to the tension mechanism and applies vacuum suction to the second air passage from a vacuum supply source.

Abstract: A sputter target assembly including a high purity copper sputter target diffusion bonded to a backing plate, preferably composed of either aluminum, aluminum alloy, aluminum matrix composite materials, copper, or copper alloy, and a Ni-alloy interlayer, preferably composed of Ni—V, Ni—Ti, Ni—Cr, or Ni—Si, located between and joining the target and backing plate, and a method for making the assembly. The method of making involves depositing (e.g., electroplating, sputtering, plasma spraying) the interlayer on a mating surface of either the sputter target or backing plate and pressing, such as hot isostatically pressing, the sputter target and backing plate together along mating surfaces so as to form a diffusion bonded sputter target assembly.

Abstract: A method for imaging inclusions in metal or metal alloy castings is described. One embodiment of the present method first involves casting a metal or metal alloy article using an investment casting mold where the mold facecoat, and perhaps one or more of the mold backup layers, comprises an imaging agent distributed substantially uniformly throughout in amounts sufficient for imaging inclusions. The facecoat preferably comprises an intimate mixture of a refractory material and the imaging agent. Intimate mixtures can be produced in a number of ways, but a currently preferred method is to cocalcine the refractory material, such as yttria, with the imaging agent, such as gadolinia. The facecoat also can comprise plural mold-forming materials and/or plural imaging agents. The difference between the linear attenuation coefficient of the article and the linear attenuation coefficient of the imaging agent should be sufficient to allow imaging of the inclusion throughout the article.

Abstract: A machine and method for bonding puncture-type conductive contact members of an interconnect to the bond pads of a bare semiconductor die includes the use of one or two ultrasonic vibrators mounted to vibrate one or both of the die and interconnect. A short axial linear burst of ultrasonic energy enables the contact members to pierce hard oxide layers on the surfaces of the bond pads at a much lower compressive force and rapidly achieve full penetration depth.

Abstract: A computer-controlled apparatus and method for producing metallic parts by laser melting selected regions of a layer(s) of metal powder at a target area are disclosed. The system includes devices for preheating and maintaining a relatively high temperature, e.g. 400° C., of the metal powder so as to join the metal powder together with relatively low laser power, e.g. a 200W CO2 laser. A major powder depositing mechanism with a scraper and a depositing system for a secondary powder are included in the apparatus that allows the powders to be delivered to the target area for selective melting. The metal powder is preheated at either a dispensing cylinder or the target area through thermal conduction and/or is also heated by a heating plate positioned above the platform through radiation. The corresponding machine structures, such as a motion system and a working chamber, are designed to be able to withstand and operated under the high temperature environment.

Abstract: A pogo welding apparatus especially for spot welding metal sheets at selected locations spaced away from their edges wherein the sheets are held in a temporary assembly with the selected locations engaged and separate programmable positioners move a primary (pogo) electrode and a backup electrode sequentially against opposite sides of the selected locations to spot weld the sheets at the selected locations in sequence. Various alternative programmable positioners, including robots of varying types, may be used to carry the electrodes. A multi head back-up electrode is adapted for efficient use of the apparatus and method in difficult to reach workpiece locations.

Abstract: Fluid permeable graphite article in the form of a perforated flexible graphite sheet having increased electrical and thermal conductivity transverse to the surfaces of the sheet.

Abstract: A process for producing a thin die-cast molded article of an aluminum material having a portion having a thickness in the range of 0.4 to 1.2 mm using a mold having a gate having an opening of 0.2 mm or greater and the same as or smaller than the thickness of the portion of the molded article separated from a gate portion, members constituting the gate having been treated by nitrogenation at the surface. The thin die-cast molded article of an aluminum material can be produced efficiently with excellent flow of the melted metal of the aluminum material through the gate portion.

Abstract: A method and apparatus for reconditioning tires while on lift trucks where a cutting tool is mounted to the lift truck and brought in contact with the tire and the tire is rotated, thereby removing material to return the tire to a more circular shape.